System and method having an improved self mating beam

ABSTRACT

A system and method for providing a stronger lanai, area or pool enclosure. The system utilizes a beam having an interior channel that provides increased thread receiving surface for receiving one or more fasteners and an interlocking joint for further strengthening the connection between a plurality of beam members that form the beam.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/015,117 filed Jan. 16, 2008, which is incorporated herein byreference and made a part hereof.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a lanai system, and more particularly, to asystem that utilizes a beam having improved strength and durability.

2. Description of the Related Art

From its infancy stages, the aluminum enclosure industry and patioscreen enclosure roof systems were fabricated with a product known as Ibeams. Although these I beams were structurally sound in nature, therewere several recurring application problems with this type of product.For example, the I beams were cumbersome to install, aestheticallyunpleasing to the home owner, and sometimes the I beam could not beconfigured to all applications needed in the industry. The I beamproduct was ultimately replaced by a product known today as a box beam.

A typical prior art box beam is shown in FIG. 1 comprising two identicalhalves A and B. The halves simply overlapped as shown and were stitchedor screwed together with a plurality of screws C to make one completeself-mating beam D.

One problem with the prior art box beams is a high failure rate duringstrong winds, especially hurricane-force winds. The box beam failed formany reasons, including the fact that the beam web was simply overlappedand laid on top of each other as illustrated in FIG. 1 with nothing tohold them together except the screw C.

Note that the fasteners only penetrated the thickness of the beams,which meant that the thread-engagement surface for the screws to bite orthread into was the wall thickness of the beam, thereby limitingstrength, particularly with thin-walled beams.

It was also not uncommon that the fastener C would not be placed in thedirect center of the beam during installation, but would cause anon-conforming attachment problem in that the securing strength wouldnot be the same along the length of the beam.

During high winds or hurricane conditions, the webs edge of thehistorical box beam will deflect, causing and creating failure in theenclosure. Once this deflection occurs, the fasteners start to pull outof the web of the beam resulting in partial or complete enclosurefailure or destruction.

Self-mating beams of the type shown in FIG. 1 are manufactured with thesame standards, causing ongoing potential failures, especially as thebeams get longer and have to carry heavier loads. Bigger and heavierbeams have been created; however, the technology for extruding andinstallation of these products is the same, resulting in ongoingfailures.

Some homeowners or builders are building larger and more dynamic poolenclosures and lanais with the same historical products, resulting inincreased failure rates, especially during high winds in hurricaneseasons.

Unfortunately, as enclosure sizes increase the box beams that were usedto make the enclosures had to be made with much thicker and heavierextrusions in order to achieve the span lengths desired. Unfortunately,these extrusions were much more expensive and resulted in increasedfailure rates and actually resulted in increased costs.

There is, therefore, a need to provide an improved box beam thatovercomes one or more problems of the prior art.

SUMMARY OF THE INVENTION

One object of the invention is to provide an improved box beam.

Another object of the invention is to provide a stronger box beam.

Another object of the invention is to provide a stronger box beam thathas an aesthetically pleasing appearance.

Another object of the invention is to provide a box beam having aninterior track that provides more threadable area for receiving one ormore fasteners.

Another object of the invention is to provide a beam having an improvedinterlocking joint, such as a dovetail joint.

Another object of the invention is to provide the aforementionedinterior track with an interlocking joint.

Another object of the invention is to provide an indicia, groove, ormark on an outside of the beam that ensures correct and consistentfastener placement during installation.

In one aspect, one embodiment of the invention comprises a beam for anoutdoor enclosure, the beam comprising a first elongated member, asecond elongated member, the first and second elongated members beingadapted to be coupled together to provide the beam and an interior trackon at least one of the first elongated member or the second elongatedmember, the interior track defining a channel or opening for receivingand supporting at least one fastener for securing the first and secondelongated members together.

In another aspect, another embodiment of the invention comprises a beamcomprising a first beam member, a second beam member, each of the firstand second beam members comprising a generally U-shape having a firstportion, a second portion and a middle portion joining the first andsecond portions, the first and second beam members being adapted to becoupled together such that the second portions of the first and secondbeam members overlap the first portions of the second and first beammembers, respectively, and an inner surface of the first portion of atleast one of the first beam member or second beam member including atleast one fastener support at every 16″ to 24″ intervals for receiving afastener that is screwed into the beam.

In still another aspect, another embodiment of the invention comprises asystem for enclosing or covering an outdoor area, the system comprisinga plurality of beams coupled to provide a frame onto which a screen maybe mounted, each of the plurality of beams comprising, a first elongatedmember, a second elongated member, the first and second elongatedmembers being adapted to be coupled together to provide each beam and aninterior track on at least one of the first elongated member or thesecond elongated member, the interior track defining a channel oropening for receiving and supporting at least one fastener for securingthe first and second elongated members together.

In still another aspect, another embodiment of the invention comprises amethod for providing an improved enclosure, comprising the steps ofproviding a plurality of support members that make up a track comprisingan interlocking joint and an interior groove, enabling a user tointerlock the support beams together and providing an interior U-shapedintegral track for threadably receiving a fastener to further facilitateinterlocking the support members together.

In yet another aspect, another embodiment of the invention comprises abeam for an outdoor enclosure, the beam comprising first and secondelongated members, each of the elongated members having a generallyU-shaped cross-section including first and second leg portions and anintermediate portion that joins the first and second leg portions, eachof the first leg portions having a first acute angled groove on an outersurface of the first leg portions and each of the second leg portionshaving a second acute angled groove on an inner surface of the secondleg portions, the second leg portions of the first and second elongatedmembers overlapping the first leg portions of the second and firstelongated members, respectively, with the acute angled grooves of thefirst and second leg portions of each of the elongated members receivingcorrespondingly angled outer ends of the second and first leg portionsof the other of the elongated members to provide interlocking dovetailjoints between the elongated members.

In still another aspect, another embodiment of the invention comprises aself-mating beam comprising a first elongated member, a second elongatedmember, and the first and second elongated members being adapted tocomprise an interlocking joint when they are mated together.

The embodiments may also comprise one or more of the features recited inthe claims and one or more of the following optional features.

Each of the second leg portions include an indicia on an exteriorsurface thereof, which is generally aligned with the interior track onthe second or first elongated members, respectively, after the elongatedmembers are coupled together to facilitate screwing the at least onefastener into the interior track.

Each of the first and second elongated members is a one-piece extrudedconstruction.

An inner surface of each first portion includes the at least onefastener support for receiving a plurality of fasteners that are screwedinto the beam.

At least one fastener support comprises an interior track that iselongated and that lies in a plane that is generally parallel to alongitudinal axis of the beam.

The interior track comprises a first track wall and a second track wallthat is generally opposed and parallel to the first track wall, thefirst track wall and the second track wall situated a predetermineddistance from the first track wall, the at least one fastener supportcomprising a threaded shank including at least a portion having a majordiameter that is larger than the predetermined distance so that the atleast one fastener support becomes threadably received in the trackwalls when the at least one fastener support is screwed into the beam.

The interior track is not visible after the first and second elongatedmembers are coupled together.

The at least one fastener support defines a continuous channel thatextends along substantially an entire length of the first and secondelongated members.

The at least one of the first portion or the second portion includes anindicia for facilitating or providing a guide aligning the at least onefastener support with the at least one fastener support.

The indicia is a groove situated on an outer surface of at least one ofthe second portions to provide the guide for screwing the fastener intothe at least one fastener support.

The first and second beam members are joined together by an interlockingjoint.

The interlocking joint comprises a dovetail joint.

The interlocking joint extends along a longitudinal axis and at least amajority of a length of the beam.

Each of the first and second beam members is generally U-shaped in crosssection and the at least one fastener support is integrally formed in aninterior surface of the beam.

The at least one fastener support is not visible when the first andsecond beam members are secured together.

The first portion, the second portion and the interior track comprise anintegral one-piece extruded construction.

A system for enclosing or covering an outdoor area comprises a pluralityof beams coupled to provide a frame onto which a screen may be mounted,each of the plurality of beams comprising a first elongated member, asecond elongated member, the first and second elongated members beingadapted to be coupled together to provide each beam and an interiortrack on at least one of the first elongated member or the secondelongated member, the interior track defining a channel or opening forreceiving and supporting at least one fastener for securing the firstand second elongated members together.

The interior track comprises a first track wall and a second track wallthat is situated a predetermined distance from the first track wall, theat least one fastener comprises a threaded shank including at least aportion having a major diameter that is larger than the predetermineddistance so that the at least one fastener becomes threadably receivedin the interior track when the at least one fastener is screwed into thebeam.

The interior track is not visible after the first and second elongatedmembers are coupled together.

Each of the first and second elongated members has an interior trackintegrally formed on an interior surface thereof.

Each of the interior track extends along substantially an entire lengthof the first and second elongated members.

At least one of the first and second elongated members include anindicia groove for facilitating or providing a guide for screwing the atleast one fastener in the interior track.

The first and second elongated members are joined together by aninterlocking joint.

The interlocking joint comprises a dovetail joint.

The interlocking joint extends an entire length of the first and secondelongated members.

Each of the first and second elongated members, the interior track andthe indicia groove are a one-piece extruded construction.

Each of the acute angled grooves has an included angle of about 45°.

The plurality of beams are assembled to form a lanai frame or roofframe.

These and other objects and advantages of the invention will be apparentfrom the following description, the accompanying drawings and theappended claims.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

FIG. 1 is a view of a prior art box beam;

FIG. 2 is a view of a patio or pool enclosure in accordance with oneembodiment of the invention;

FIG. 3 is an exploded view of a beam in accordance with one embodimentof the invention showing a first member and a second member that is amirror image of the first member except that it is inverted;

FIG. 4 is an assembled view of the first and second members,illustrating the interlocking or dovetailed joint and a plurality offasteners screwed into an interior channel in the beam;

FIG. 5 is a sectional view of the beam showing, among other things, anindicia or groove for providing an alignment or guide for screwing thefasteners into the beam, the interior groove, as well as an explodedview of the positioning of a textile or screen relative to a screenreceiving channel; and

FIGS. 6A and 6B are illustrations showing use of the beam in one otherillustrative application of a covering, such as a car port, illustratingimproved spanability of the beam.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIG. 2, a system 10 is shown in accordance with oneembodiment of the invention. The system 10 is ideally suited to encaseat least a portion of an area 12, such as a pool area or patio areaadjacent a building or structure, such as a dwelling or house 14. Thesystem 10 is ideally suited for an outdoor area, but could be usedinside a building or structure if desired.

In the illustration being described, the system 10 comprises a pluralityof beams 16, such as track beams, wall beams, floor beams, roof beams,structural beams or the like and frame members 17 that are coupledtogether to provide a frame 18 onto which a textile or material, such asa screen 20, may be affixed by conventional means. The features of theinvention can be used with center beams, roof members, wall members,floor beams, side beams, wall beams and the like. The beams 16 may alsobe used as or in the same manner or environment that any self-matingbeam was used in the past, such as a center beam, side beam, roof beam,carrier beam, uprights or posts.

Referring now to FIGS. 3-5, it should be understood that it may bedesired to provide one or more beams 16 that span long distances D1(FIG. 2), such as distances greater than, for example, 20 feet. Oneadvantage of the invention is that it provides a self-mating beam thatcan span longer distances D1 than prior art self-mating beams withoutthe beams warping, deflecting, bending or encountering problems thatwere encountered in the past. For example, a standard prior art 2″ by 6″beam would have little (i.e., only a few feet) or no spanability as aroof member. In contrast, using features of the embodiment beingdescribed, a 2″ by 6″ beam can span a distance D1 in excess of about 15or even 20 feet. This enables or facilitates using such beam 16 in placeof a much heavier roof beam of the prior art. To achieve such objective,the invention utilizes the beam 16 which will now be described relativeto FIGS. 3-5.

For ease of illustration and description, a single beam 16 will bedescribed, but it should be understood that the frame 18 may becomprised of one or more of the beams 16, or the beams 16 may be usedwith other conventional frame supports and components. The beams 16 maybe fabricated or assembled into a truss or structural frame 18 usingconventional gussets (not shown for ease of illustration). A 2″ by 6″beam 16 may span 15 feet, whereas a 2″ by 9″ beam 16 might span 45 feet.The beams 16 of the present invention may be used to do jobs thatrequire large span lengths D1 (FIG. 2) than what could be done with thesame size beam of the past. Thus, the beam 16 enables wider spanability,improved strength and the ability to accommodate greater lengths, yetwith less weight. The beam 16 provides improved interlocking of matinghalves (described later herein) which in turn, improves spanability ofthe beam 16. The improved interlocking joint also enables manufacturinga lighter beam that enables the manufacture and assembly of largerframes 18 that cover larger areas to be screened in or enclosed.

Each of the beams 16 comprises a first member 22 and a mating overfittedand interlocking second member 24. The second member 24 is a mirrorimage of the first member 22, but inverted relative to the first member22 as shown. As illustrated in FIGS. 2 and 5, the beam 16 in theembodiment being described is an integral aluminum extrusion. Noticethat each of the first member 22 and second member 24 is elongated andadapted to be interlocked, overfitted and coupled together to providethe beam 16. In this regard, notice that the first member 22 comprises afirst leg portion 22 a, a second leg portion 22 b and a joining portion22 c that joins the first and second leg portions 22 a and 22 b asshown. The second member 24 comprises a first leg portion 24 a, a secondleg portion 24 b and a joining portion 24 c that joins the first legportion 24 a and the second leg portion 24 b.

In the illustration being described, at least one of the first member 22or second member 24 comprises an interior fastener receiving area,channel or track 26. The track 26 comprises a first elongated track wall28 and a second elongated track wall 30 that is generally opposed andparallel to the first elongated track wall 28 as shown. In theillustration being described, the first elongated track wall 28 andsecond elongated track wall 30 define a channel, spline groove or area32 for receiving a threaded shank or end of at least one or a pluralityof fasteners 34. The fastener 34 require no special fastener and can bea conventional standard fastener that is conventionally used. The trackwalls 28 and 30 comprise surfaces 28 a and 30 a that provide increasedthread-engaging surface area into which the fasteners 34 may be screwed.The first and second elongated track walls 28 and 30 also providestrengthening ribs that extend along the longitudinal length of the beam16.

The interior track 26 is adapted to threadably receive and support theat least one or a plurality of fasteners 34 that are used to secure thefirst member 22 to second member 24. In this regard, notice that thetrack 26 has a dimension TW (FIG. 3) that is slightly smaller than amajor diameter of a threaded shank 34 a of fastener 34 so that at leasta portion of the threaded shank 34 a of the fastener 34 may threadablyengage the surfaces 28 a and 30 a of the track or be secured in thetrack 26 when the fastener 34 is screwed into the beam 16.

The first member 22 comprises a plurality of spline grooves or screenreceiving areas 38 and 40 for receiving screen 20 and screen support orspline 41 (FIGS. 4 and 5) for securing the screen 20 therein. In thisregard, it should be understood that the screen 20 is wrapped around thescreen support or spline 41 and enforced or inserted into the splinegroove 32 in a manner conventionally known. In the illustration, thescreen support or spline 41 is a thin rubber spline or tubing of thetype conventionally known.

The second member 24 in the illustration being described also comprisesan interior track 26 and spline groves 38 and 40. In the illustrationbeing described, the interior track 26 on the first leg portion 24 a ofthe second member 24 is substantially the same as the interior track 26on the first leg portion 22 a, and the spline groves 38 and 40 are thesame as those on the first member 22. These parts have been labeled withthe same part numbers.

As mentioned, the first member 22 and second member 24 are interfittedand overlapped so that the first leg portion 22 a and first leg portion24 a are situated in adjacent and engaged relation to the second legportions 24 b and 22 b, respectively, as shown. In this regard, notethat ends or surfaces 22 a 1, 22 b 1, 24 a 1 and 24 b 1 are tapered,beveled, dovetailed or angled as shown.

Note that the first member 22 comprises a plurality of integralprojections 42 and 44 that define the spline groves 38 and 40 and alsodefine shaped angled or dovetailed receiving areas 46 and 48,respectively, that are adapted to compliment the shape of the surfaces22 a 1, 22 b 1, 24 a 1 and 24 b 1. Likewise, the second member 24comprises the projections 50 and 52 that define similar receiving areas54 and 56, respectively. The integral projections 42, 44, 50 and 52comprise angled surfaces 42 a, 44 a, 50 a and 52 a that cooperate withthe surfaces 24 a 1, 24 b 1, 22 b 1 and 22 a 1, respectively, to providean interlocking or dove-tail joint which facilitates locking the firstmember 22 and second member 24 together. The angled surfaces 42 a, 44 a,50 a and 52 a could be, for example, 45° or any angle, configuration oradaptation that will provide an interlocking joint along the beam toprevent interlocking joint failure. In this regard, notice in FIG. 4that the interlocking or dovetail joint facilitates preventing thesecond leg portion 22 b from separating from the first leg portion 24 aand the first leg portion 22 a from separating from the second legportion 24 b. Thus, the dovetail or interlocking joint facilitatespreventing the second leg portion 22 b from moving in the direction ofarrow A (FIG. 4), the first leg portion 24 a from moving in thedirection of arrow B, the first leg portion 22 a from moving in thedirection of arrow C and second leg portion 24 b from moving in thedirection of arrow D. It has been found that this interlocking ordovetailed joint provides a very strong connection or coupling of thefirst member 22 to the second member 24, and when used in conjunctionwith the fastener 34 and the interior track 26, a very rigid and lockedconnection or coupling is formed. Although not shown, other types ofinterlocking joints that do not employ the angled surfaces 22 a 1, 22 b1, 24 a 1 and 24 b 1, but rather, provide other interlockingconfigurations may also be used to interlock the first member 22 to thesecond member 24.

Advantageously, the rigidity and strength of the connection of the firstand second members 22 and 24 enables the beam 16 to span longer lengthsusing less material. The interlocking joint and interior track extendlongitudinally and enable the first member 22 and the second member 24to be extruded. As mentioned, the strength of the interlocking jointfacilitates providing a beam 16 in larger dimensions and lighterweights, without the beam 16 bowing, deflecting, twisting orexperiencing the problems of the past during use. For example, a usermay be able to replace a 2″ by 8″ prior art beam with a 2″ by 6″ beam16.

Notice in FIGS. 3 and 4 that the leg portions 22 a, 22 b, 24 a and 24 bmay comprise serrated surfaces 22 a 2, 22 b 2, 24 a 2 and 24 b 2,respectively, that mate and cooperate to facilitate preventing the firstmember 22 from moving in the direction of arrow E (FIG. 4) and thesecond member 24 from moving in the direction of arrow F in theillustration.

It is important to note that the leg portions 22 b and 24 b comprise anindicia, mark or groove 58, which in the embodiment being described isgenerally v-shaped. Notice that when the first member 22 and the secondmember 24 are overlapped, interlocked or fitted together, the groove 58becomes generally aligned with a center axis or plane CA (FIG. 4) of thereceiving area 32. The indicia, mark or groove 58 provides an aligningguide or indicia that the user may use to align the at least one orplurality of fasteners 34 with the channel 32 so that when the at leastone or plurality of fasteners 34 are screwed through the second legportions 22 b and 24 b, these screws become threadably received betweenthe track walls 28 and 30. As mentioned earlier, the track walls 28 and30 provides more threadable surface area for the at least one orplurality of fasteners 34 to thread into, which further strengthens thefastening of the first member 22 to the second member 24.

A method of assembly will now be described relative to FIG. 5. Ingeneral, the first member 22 and the second member 24 are overfitted orinterlocked together as shown in FIG. 4. After the first member 22 andsecond member 24 are interlocked together, a user may align an end 34 bof at least one or a plurality of fasteners 34 with the groove 58. Theuser then screws each fastener 34 through the groove 58 and therebysecures the first leg portion 22 a and first leg portion 24 a to thesecond leg portions 24 b and 22 b, respectively, as illustrated in FIGS.4 and 5. The user may screw a plurality of fasteners 34 along thelongitudinal length of the groove 58 and beam 16, as illustrated in FIG.5. Notice that in each case, the fastener 34 is threadably received inthe interior track 26. Again, the groove 58 facilitates providing anindicia or guide by which the user can align the fastener 34 with thereceiving area 32. As also mentioned earlier herein, the track walls 28and 30 of the interior track 26 provides increased thread-engagementsurface area for receiving the threaded shank 34 a of the fastener 34.The fastener(s) 34 and the interlocking joint provide improved andstronger coupling or interlock between of the first and second members22 and 24 in turn the beam 16 is stronger than self-mating beams of thepast.

After the first member 22 and second member 24 are secured together inthe manner described herein and as shown in FIGS. 4 and 5, the screen 20and rubber tubing or screen spline 41 are inserted into the splinegroves 38 and 40 in a manner conventionally known. As mentioned earlier,the beams or one or more of the sections 16 a, 16 b, 16 c and 16 d aretypically fabricated or assembled into a complete or partial truss orframe 18 using conventional gussets 61 (FIG. 2). The frame 18 can thenbe assembled into sections, such as the sections 16 a, 16 b, 16 c and 16d. The sections may then be transported, with or without screen 20, to ajob site. During assembly, one or more sections, such as sections 16 a,16 b, 16 c or 16 d (FIG. 6), may be assembled offsite. Holes or openings(not shown) are then drilled or provided into the trusses that willreceive, for example, 2″ by 2″ purlings or intermediate members 19 (FIG.2) to secure adjacent trusses together. As is known in the art, thesections 16 a, 16 b, 16 c and 16 d may be transported with the first andsecond members 22 and 24 fastened together for transportation. At thejob site the beams 16 between each section are disassembled, leaving,for example, a first member 22 of the beam 16 with section 16 a and thesecond member 24 of beam 16 with section 16 b. The sections 16 a, 16 b,16 c and 16 d may then be individually raised into the air and mountedon the supports, such as walls or supports 17 (FIG. 2), of the structureor frame 18.

Advantageously, the grooves 58 (FIG. 3) enable the installer to quicklyand easily screw the fasteners or screws 34 into the beam 16 and intothe interior track 26. This facilitates quick and easy assembly of thesections together on the job site, especially after the sections areraised in the air. The frame 18 may be constructed off-site or on-siteif desired. After the frame 18 and screen 20, which may be mounted onthe frame on-site or off-site, are assembled, frame 18 is then securedor mounted to the structure, such as a wall or roof of a structure,deck, lanai or patio 12, by conventional means such as screws orfasteners or the like.

Advantageously, a system and method for providing a strengthenedself-mating beam 16 is provided and adapted to provide a beam that canspan longer distances. This in turn means that larger lanais and patiocovers may be provided. Also, longer and lighter beams may be usedwithout the beams experiencing the problems of the past, such aswarping, deflecting, twisting, bending and the like.

Advantageously, the system and method according to the embodimentsdescribed herein enabled the beam 16 to span greater lengths D1 (FIG. 2)without the need to utilize more material and thicker wall tolerances inorder to accommodate any possible deflection. The interlocking jointalone or in combination with the interior groove and fastener results ina high strength beam that may provide a safer, stronger and more durableenclosure. A stronger interlock between the first and second members 22and 24 also facilitates enabling the overall beam size, weight, materialthickness and the like to be reduced. For example, FIG. 6A shows anotherenvironment for use of the beam 16, namely a wide spanning car port 80capable of handling two or more cars without the use of center posts.FIG. 6B shows another embodiment showing a wide-spanning cover, such asa recreation or picnic area cover 82 supported by the corner posts 84.

Thus, it should be apparent that the invention provides means foradapting a self-mating beam to many different environments when largebeam span lengths are required and facilitates reducing or eliminatingthe need for further supports, such as center posts or uprights.

Other advantages include:

a continuous interior track 26 that is extruded within the first andsecond members 22 and 24 that improves fastener engagement;

the continuous interior track 26 has the interlocking joint that allowsand takes on the same characteristics as “tendon” similar of that foundin bridge construction;

the continuous interior track 26 also provides a “double T” creating arigid connection throughout the entire length of the extrusion, asopposed to a “flat” surface which has little strength;

all fastener threads of threaded shank 34 a are engaged in this interiortrack 26, which creates a positive moment connection with each fastener34 that is installed;

an external mark, indicia or groove on the outside of the web or beam 16assures correct and consistent fastener 34 placement duringinstallation;

a 45 degree angle extruded along the spline groove of the web or beam16, creating a continuous female locking system to accept the opposingmale half; and

the angle provides a continuous lock down to the at least a portion orthe entire length of the beam and locks them together which allows themto take on strength characteristics similar to a “hollow” profile.

The first or second members 22 and 24 are extruded aluminum and,advantageously, require no additional machining to proved the channel32. The alloy used to make the beam 16 could be made from a higherstrength alloy, such as 6005 aluminum.

The beam 16 could also be used with an adhesive system that utilizes anadhesive to bond the beam sides together.

The beam's 16 strength enables greater spanability without the use ofsupports as was traditionally needed, such as uprights, posts and thelike. This makes the beam 16 advantageously suited for use as anenclosure or in any environment where a traditional interlocking beamwas used with supports. For example, in a traditional car port orstandalone roof cover, a wide span of self-mating beams was difficultwithout the use of support posts, such as center posts locatedunderneath the roof. With the embodiment being described, a wider spanis enabled without the use of support posts or center posts. This isillustrated in the car port illustrated in FIG. 6. Notice that nosupport posts are provided or necessary because of the strength of theinterlocking beam 16.

While the system and method herein described constitute preferredembodiments of this invention, it is to be understood that the inventionis not limited to this precise method and form of apparatus and thatchanges may be made in either without departing from the scope of theinvention, which is defined in the appended claims.

1. A beam for an outdoor enclosure, said beam comprising: a firstelongated member; a second elongated member; said first and secondelongated members being adapted to be coupled together to provide thebeam; and an interior track on at least one of said first elongatedmember or said second elongated member, said interior track defining achannel or opening for receiving and supporting at least one fastenerfor securing said first and second elongated members together.
 2. Thebeam as recited in claim 1 wherein said interior track comprises a firsttrack wall and a second track wall that is situated a predetermineddistance from said first track wall, said at least one fastenercomprises a threaded shank comprising at least a portion having a majordiameter that is larger than said predetermined distance so that said atleast one fastener becomes threadably received in said interior trackwhen said at least one fastener is screwed into said beam.
 3. The beamas recited in claim 1 wherein said interior track is not visible aftersaid first and second elongated members are coupled together.
 4. Thebeam as recited in claim 1 wherein each of said first and secondelongated members include an interior track integrally formed on aninterior surface thereof.
 5. The beam as recited in claim 1 wherein saidinterior track extends along a longitudinal axis and substantially anentire length of said beam.
 6. The beam as recited in claim 1 whereinsaid interior track defines a continuous channel that extends alongsubstantially an entire length of said beam.
 7. The beam as recited inclaim 1 wherein at least one of said first and second elongated membersinclude an indicia or groove for facilitating, or providing a guide forscrewing said at least one fastener into said interior track.
 8. Thebeam as recited in claim 1 wherein said first and second elongatedmembers are joined together by an interlocking joint.
 9. The beam asrecited in claim 8 wherein said interlocking joint comprises a dovetailjoint.
 10. The beam as recited in claim 8 wherein said interlockingjoint extends an entire length of said beam.
 11. The beam as recited inclaim 1 wherein each of said first and second elongated members aregenerally U-shaped in cross section.
 12. The beam as recited in claim 1wherein each of said first and second elongated members are generallyU-shaped in cross section and comprise a first leg portion, a second legportion and a joining portion that joins said first and second legportions, each of said first leg portions include an inner trackdefining a channel that is generally parallel to a longitudinal axis ofsaid beam.
 13. The beam as recited in claim 12 wherein each of saidsecond leg portions include an indicia on an exterior surface thereof,which is generally aligned with said interior track on the second orfirst elongated members, respectively, after said elongated members arecoupled together to facilitate screwing said at least one fastener intosaid interior track.
 14. The beam as recited in claim 12 wherein each ofsaid first and second elongated members is a one-piece extrudedconstruction.
 15. The beam as recited in claim 1 wherein said beam isassembled to provide a structure for enclosing or covering an outdoorarea.
 16. A beam comprising: a first beam member; a second beam member;each of said first and second beam members comprising a generallyU-shape having a first portion, a second portion and a middle portionjoining said first and second portions, said first and second beammembers being adapted to be coupled together such that said secondportions of said first and second beam members overlap said firstportions of said second and first beam members, respectively; and aninner surface of said first portion of at least one of said first beammember or second beam member including at least one fastener support 16″to 24″ intervals for receiving a fastener that is screwed into saidbeam.
 17. A method for providing an improved enclosure, comprising thesteps of: providing a plurality of support members that make up a trackcomprising an interlocking joint and an interior groove; enabling a userto interlock the support beams together; and providing an interiorU-shaped integral track for threadably receiving a fastener to furtherfacilitate interlocking the support members together.
 18. A beam for anoutdoor enclosure, said beam comprising: first and second elongatedmembers; each of said elongated members having a generally U-shapedcross-section including first and second leg portions and anintermediate portion that joins said first and second leg portions; eachof said first leg portions having a first acute angled groove on anouter surface of said first leg portions and each of said second legportions having a second acute angled groove on an inner surface of saidsecond leg portions; said second leg portions of said first and secondelongated members overlapping said first leg portions of said second andfirst elongated members, respectively, with said first acute angledgroove and said second acute angled groove of said first and second legportions of each of said elongated members receiving correspondinglyangled outer ends of said second and first leg portions of the other ofsaid elongated members to provide interlocking dovetail joints betweensaid elongated members.
 19. The beam as recited in claim 18 wherein eachof said acute angled grooves has an included angle of between about 30°and about 60°.
 20. The beam as recited in claim 18 wherein each of saidleg portions of said first and second elongated members has teeth inoverlapping sides of said leg portions that mesh with each other. 21.The beam as recited in claim 18 wherein said interlocking dovetailjoints form channels extending at least a majority of a length of saidelongated members containing a bonding adhesive for adhesively bondingsaid elongated members together.
 22. The beam as recited in claim 18wherein an inner surface of each of said first leg portions has aninterior track extending at least a majority of a length of saidelongated members for receiving a plurality of longitudinally spacedfasteners that are screwed through said overlapping second and first legportions, respectively, into said interior track.
 23. The beam asrecited in claim 22 wherein each said interior track has uniformlyspaced apart track walls, and each of said fasteners has a threadedshank portion with a major diameter that is slightly larger than thespacing between said track walls so that said fasteners becomethreadedly received in said track walls during screwing of saidfasteners through said overlapping second and first leg portions,respectively, in substantial alignment with an axial center of each saidinterior track.
 24. The beam as recited in claim 23 wherein an outersurface of each of said second leg portions has indicia in substantialalignment with the axial center of each said interior track tofacilitate screwing of said fasteners into said track walls.
 25. Thebeam as recited in claim 23 wherein said indicia is a groove extendingat least the majority of the length of said elongated members to providea guide for screwing said fasteners into said track walls duringscrewing of said fasteners through said overlapping second and first legportions, respectively.
 26. The beam as recited in claim 22 wherein eachof said elongated members is a one piece extrusion.
 27. The beam asrecited in claim 18 wherein the plurality of said beams are assembled toform a roof over a patio area, car port area or recreation area.
 28. Aself-mating beam comprising: a first elongated member; a secondelongated member; and said first and second elongated members beingadapted to comprise an interlocking joint when they are mated together.29. The self-mating beam as recited in claim 28, wherein each of saidfirst and second elongated members comprise a groove for receiving atleast a portion of said second or first elongated members, respectively,when said first and second elongated members are mounted together, saidgroove and said at least a portion of said first and second elongatedmembers cooperating to provide said interlocking joint.
 30. Theself-mating beam as recited in claim 29, wherein said groove is anangled groove and said at least a portion of said first and secondelongated members has an angled surface that is received in said angledgrove.
 31. The self-mating beam as recited in claim 28, wherein aninterior surface of at least one of said first or second elongatedmembers comprises an interior track for receiving a screw.
 32. Theself-mating beam as recited in claim 28, wherein each of said first andsecond elongated members comprise an interior track that extendssubstantially along a longitudinal length of said beam.
 33. Theself-mating beam as recited in claim 28, wherein each of said first andsecond elongated members comprise a first leg portion having a firstgroove, a second leg portion having a second groove and a joiningportion for joining said first and second leg portions, said second legportions of said first and second elongated members overlapping saidfirst leg portions of said second and first elongated members,respectively, with said first groove and said second groove of saidfirst and second leg portions of each of said elongated membersreceiving portions of said second and first leg portions of the other ofsaid elongated members to provide interlocking joints between saidelongated members
 34. The self-mating beam as recited in claim 33,wherein each of said interlocking joints each comprise a dovetail joint.